Tile saw

ABSTRACT

A saw includes a base having a first length extending generally along a first direction, a table disposed on the base, a saw unit disposed on the base, wherein one of the table and the saw unit is movable relative to the base along the first direction over a range which exceeds the first length. The saw may also include a first stationary rail connected to the base and extending generally along the first direction and a first movable rail engaging the first stationary rail and extending generally parallel to the first stationary rail, the first movable rail being connected to the one of the table and saw unit. Preferably, the first movable rail is slidingly received over the first stationary rail. The saw may also include a first rack disposed on the first movable rail, and a first pinion disposed on the base, wherein the first pinion meshes with the first rack so that the first movable rail moves along the first direction upon rotation of the first pinion. Preferably, the saw further includes a second stationary rail connected to the base and extending generally along the first direction and substantially parallel to the second stationary rail, and a second movable rail engaging the second stationary rail and extending generally parallel to the first movable and second stationary rails, the second movable rail being connected to the one of the table and saw unit.

This application claims benefit to Provisional application Ser. No.60/106,658, filed Nov. 2, 1998.

FIELD OF THE INVENTION

This invention relates generally to tile or masonry saws and, moreparticularly, to tile saws with expanded capacity.

BACKGROUND OF THE INVENTION

A typical tile saw includes a base which supports a generally flat tabletop. A saw unit may be disposed on the base or table for cutting aworkpiece, such as a tile or masonry brick, disposed on the table.However, the maximum cutting capacity of such tile saws is limited bythe size of the machine, i.e., the envelope.

Accordingly, persons skilled in the art have devised a tile saw wherethe base has two tracks and the table has bearings or wheels riding onthe tracks, so that the table can be slid relative to the saw unit forincreased capacity. Such tile saws, however, are usually susceptible todust collecting between the tracks and wheels, which creates bindingbetween the base and the table. Ultimately, the binding may causeuneven, inaccurate cuts, which may translate into loss of time,materials and/or profit for the user.

Further, the capacity of such tile saws is usually limited to the lengthof the tracks. In other words, if a user wants increased capacity, hemay have to lengthen the tracks. However, longer tracks may result inless portability of the tile saw.

It is therefore an object of this invention to provide a saw withincreased cutting capacity without sacrificing portability.

SUMMARY OF THE INVENTION

In accordance with the present invention, an improved tile saw isemployed. The saw comprises a base, a table disposed on the base, a sawunit disposed on the base, a first stationary rail having a first lengthextending generally along a first direction, the first stationary railbeing connected to one of the table and saw unit, and a first movablerail engaging the first stationary rail and extending generally parallelto the first stationary rail, the first movable rail being connected tothe other of the table and saw unit, wherein the first movable rail ismovable with respect to the first stationary rail such that the other ofthe table and saw unit is movable generally along the first directionover a range which exceeds the first length. Preferably, the firstmovable rail is slidingly received over the first stationary rail.

Additional features and benefits of the present invention are described,and will be apparent from, the accompanying drawings and the detaileddescription below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate preferred embodiments of theinvention according to the practical application of the principlesthereof, and in which:

FIG. 1 is a perspective side view of a first embodiment of a tile sawaccording to the present invention;

FIG. 2 is a plan view, partially in cross section, of the tile sawillustrated in FIG. 1;

FIG. 3 is a perspective view showing an embodiment of a telescoping rackand pinion assembly according to the present invention;

FIG. 4 is a side elevational view, partially in cross-section, alongplane IV—IV of FIG. 1;

FIGS. 5A and 5B are schematic illustrations of the telescoping fenceassembly according to the present invention;

FIGS. 6A and 6B are enlarged perspective views illustrating the bumpsschematically shown in FIGS. 5A and 5B;

FIG. 7 is a perspective side view of a second embodiment of a tile sawaccording to the present invention;

FIG. 8 is a side elevational view of the knob drive assembly of thesecond embodiment;

FIG. 9 is a perspective side view of a third embodiment of a tile sawaccording to the present invention;

FIG. 10 is a perspective side view of a fourth embodiment of a tile sawaccording to the present invention; and

FIG. 11 is a perspective side view of a fifth embodiment of a tile sawaccording to the present invention.

DETAILED DESCRIPTION

The invention is now described with reference to the accompanyingfigures, wherein like numerals designate like parts. FIG. 1 illustratesa first embodiment of the present invention, where tile saw 10 comprisesa base 11 which supports a generally rectangular work table 12. Slidablerelative to table 12 is saw unit 13, which comprises a blade 14 and amotor 15 driving the blade 14. The saw unit 13 is slidably disposed onguide rods 16, so that the saw unit 13 can be positioned at any positionalong rods 16. Persons skilled in the art will recognize that one guiderod 16 may be used, but it is preferred to use at least two rods 16 inorder to maximize stability.

Further, saw unit 13 can be adapted to bevel, i.e., change the angle ofblade 14 relative to the table 12, as is known in the art.

Saw unit 13 also has a water conduit 8 for lubricating and cooling theblade 14, as is known in the art. Water sent through conduit 8 willdrain into base 11 through table 12 and may be repumped through conduit8 as is known in the art.

The saw unit 13 is preferably adapted so that a drill press 30 can beattached thereto. By changing the relative position of saw unit 13and/or table 12, the drill press 30 can be positioned over a tileworkpiece for making round or arcuate cuts. Accordingly, the drill press30 may be provided with an annular or circular cutting tool, preferablymade of diamond.

Rail assemblies 100 are used to provide slidable movement between thesaw unit 13 and table 12. Persons skilled in the art are directed toU.S. Pat. No. 5,722,308, assigned to the present assignee, for furtherinformation on the rail assemblies 100 and their operation. Further,U.S. Pat. No. 5,722,308 is hereby incorporated by reference into thepresent specification.

Rail assemblies 100 are each comprised of an inner rail 18 and an outerrail 19. Inner rails 18 are preferably disposed on the front and rear oftable 12. Preferably, the inner rails 18 have a generally C-shapedcross-section and a length generally equal to the width of table 12.Inner rails 18 are fixedly secured to table 12 using a plurality offasteners 101 which are preferably spaced along the entire length ofinner rail 18. As shown in FIG. 4, fasteners 101 include a bolt 102, anut 103 and a bushing 122. Bolt 102 extends through inner rail 110 andthrough a bracket 124 which is secured to or is an integral part oftable 12. Bushing 122 is preferably made from UHMW-PE or low frictionpolymeric material and is located between inner rail 18 and bracket 124with the assembly being secured by nut 103. Bushing 122 may extend overthe entire length of inner rail 18.

A glide strip 18C may be disposed on or wrapped around inner rail 18 tofacilitate the movement of outer rail 19 with respect to inner rail 18.In the preferred embodiment, glide strip 18C is made of UHMWpolyethylene or a nylon based material injection molded over inner rail18. Glide strip 18C preferably extends over the entire length of innerrail 18.

Outer rails 19 are generally C-shaped members slidingly received overthe inner rails 18. Outer rails 19 are preferably made of steel androll-formed into the desired shape. A rail mechanism 200 allows a userto move the outer rails 19 relative to the inner rails 18, as explainedbelow.

Carriages 17 supporting guide rods 16 and saw unit 13 are fixedlydisposed on the outer rails 19. Persons skilled in the art willrecognize that the tile saw 10 may be designed so that only one carriagesupports the guide rods 16 and saw unit 13.

By providing outer rails 19 which telescope with inner rails 18, the sawunit 13 is deployable beyond the envelope of work table 12 in order toprovide additional cutting capacity, as shown in FIG. 1, yet maintaininga compact envelope for simplifying transportation of tile saw 10. Thecompact envelope of tile saw 10 facilitates both storage of tile saw 10and the movement of tile saw 10 from one job site to the another.

Persons skilled in the art will recognize that, to perform the cut, theoperator need only push saw unit 13 towards the workpiece. The rigidconnection between the outer rails 19, the carriages 17 and the rails 16will maintain the outer rails 19 moving together the same distance.Persons skilled in the art will recognize that other means to obtain thesame result exist.

For example, outer rails 19 may comprise a rack 376 which can beintegral with outer rail 19 or it can be a separate component attachedto a lower extending flange of outer rail 19 by a plurality of screws.Rack 376 preferably extends over the entire length of outer rail 19.Rack 376 includes a plurality of rack teeth 378 which may extend overthe entire surface of the rack. An enlarged tooth may be provided at theend of each rack 376 to limit the travel of outer rail 19 with respectto inner rail 18 in either direction, as disclosed in U.S. Pat. No.5,722,308, which is again hereby incorporated by reference.

Rail mechanism 200 comprises a pinion shaft 150, a pair of pinion gears340 and an adjustment wheel 154. Pinion gears 340 and adjustment wheel154 are fixedly secured to pinion shaft 150 for rotation therewith.Pinion shaft 150 is rotatably secured to base 11 (preferably by bearingmounts 346) such that pinion gears 340 are engaged with rack teeth 378on each outer rail 19 with adjustment wheel 154 preferably extendingbeyond the front outer rail 19 for accessibility by an individual. Thus,rotation of adjustment wheel 154 cause rotation of pinion shaft 150 andpinion gears 340 which, due to their engagement with rack teeth 378 ofrack 376, cause longitudinal movement of each outer rail 19 with respectto each inner rail 18 and the movement of saw unit 13 relative to sawtable 12.

Due to the fact that both front and rear pinion gears 340 rotatesimultaneously and by the same amount due to their rotation with pinionshaft 150, both outer rails 19 will move together and the same distancedue to the engagement of rack teeth 378 of each rack 376 with arespective pinion gear 340. This simultaneous and equal movement of eachouter rail 19 will thus ensure that the relationship between saw unit 13and table 12 will be maintained during the movement of the saw unit 13.

Accordingly, the present invention allows the saw unit 13 to be movedover a range of lengths which exceeds the length of the stationary innerrails 18. Preferably, the saw unit 13 can be moved beyond the width ofthe work table 12, outwardly of either side edge, without requiring thatthe stationary rails have a length which is greater than the width ofthe table to provide for such movement.

The telescoping rails of the present invention have sufficient clearancebetween each inner rail and outer rail disposed thereon to accommodatethe non-straightness of the rails. This clearance can cause excessiveend play of the outer rail as it moves toward its totally extendedposition. Thus, it may be desirable, in the present invention, toprovide a system for stabilizing the outer rail as it moves to it fullyextended position.

Accordingly, FIGS. 5A and 5B schematically represent an inner rail 18and an outer rail 19. As before, inner rail 18 is adapted to be securedto work table 12. Outer rail 19 telescopically engages inner rail 18 asshown previously with sufficient clearance maintained between the innerand outer rails to accommodate any non-straightness. Each end of innerrail 18 would include an outwardly extending bump 504 and each end ofouter rail 19 would include an inwardly extending bump 506. Bumps 504contact the inner surface of outer rail 19 while bumps 506 contact theouter surface of inner rail 18. These contact points help stabilize themovable rail against vertical movement in any extended position of themovable rails. However, bumps 504 and 506 must be provided in a mannerwhich allows for outer rail 19 to move from the position shown in FIG.5A to that shown in 5B. That is, it is necessary for inwardly extendingbumps 506 to pass through outwardly extending bumps 504.

FIG. 6A illustrates a construction of inner rail 18 and outer rail 19which provides bumps 504 and 506 which pass through each other. Asexplained above, guide strip 18C may be injection molded over inner rail18 as shown. Glide strip 18C may be molded so as define a pair of pads508 on the upper and lower surfaces of inner rail 18 at each end. Eachpair of pads 508 defines a channel 510 extending longitudinally alongthe length of inner rail 18 for a short distance. The pair of pads 508are designed such that they slidingly engage the interior surfaces ofouter rail 19 to reduce or eliminate the clearances between the tworails. Pads 508 also could be a separate component assembled to innerrail 18.

FIG. 6B illustrates outer rail 19 incorporating inwardly extending pads512 integrally formed as a part of outer rail 19 at each end. One pad512 is formed into an upper wall of outer rail 19 while the second pad512 is formed into the lower wall of outer rail 19. Pads 512 may beformed by stamping the rails inwardly in the roll forming process of therails. Pads 512 are positioned to align with channels 510 defined bypads 508 such that outer rail 19 is allowed to move outwardly beyondinner rail 18 in both directions as is schematically illustrated inFIGS. 5A and 5B. Pads 508 function as bumps 504 and pads 512 function asbumps 506 as described with reference to FIGS. 5A and 5B. Thus, thecontact of pads 508 and 512 with outer rail 19 and inner rail 18,respectively, stabilizes the outer rails in the extended position.Persons skilled in the art are directed to U.S. Pat. No. 5,722,308, forother means for providing bumps 504 and 506.

Furthermore, persons skilled in the art are directed to U.S. Pat. No.5,722,308, for further means for moving the outer rails 19 in relationto the inner rails 18.

FIG. 7 illustrates a second embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the first embodiment. Themain differences between this embodiment and the previous one is that:(1) inner rails 18 may be attached on the same side of base 11; (2)carriage 17 may be connected to both outer rails 19; and/or (3) rods 16may be cantilevered. Preferably a first inner rail 18 is disposed abovea second inner rail 18 in a parallel manner. Also at least one of rods16 may have a stop 16S to prevent saw unit 13 from being removed offrods 16. Having such construction allows the user to cut a workpiece Whaving a width greater than the width of table 12 and/or base 11.

In order to move the outer rails 19, the operator need only push on sawunit 13. Alternatively, a knob assembly 400 may be provided in base 11.Knob 154 is connected to a pinion 410, which meshes with two pinions411. Preferably pinions 411 have the same diameter and/or distancebetween teeth. Pinions 411 then mesh with the corresponding outer rails19. Accordingly, when user rotates knob 154, pinions 410 and 411 rotate,moving outer rails 19 in the same direction and speed.

FIG. 9 illustrates a third embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the previous embodiments. Themain difference between this embodiment with the first embodiment isthat the table 12 is fixedly attached to the outer rails 19, so that thetable 12 can be moved relative to saw unit 13 and base 11. Accordingly,carriages 17 are fixedly connected to base 11. In addition, a sheet 20may be attached to table 12, so that water from table 12 is collected onsheet 20 and drained into base 11. Sheet 20 is preferably pliable sothat it can follow table 12 through the entire range of motion. Asmentioned above, the user need only push the table 12 13 to cut theworkpiece. Alternatively, the user may turn knob 154, thus rotatingpinion shaft 150 and forcing outer rails 19 (and thus table 12) to move.

FIG. 10 illustrates a fourth embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the previous embodiments. Themain differences between this embodiment and the third embodiment isthat: (1) inner rails 18 may be attached on the same side of base 11;and/or (2) rods 16 may be cantilevered. Preferably a first inner rail 18is disposed above a second inner rail 18 in a parallel manner. Also atleast one of rods 16 may have a stop 16S to prevent saw unit 13 frombeing removed off rods 16. Having such construction allows the user tocut a workpiece W having a width greater than the width of table 12and/or base 11.

Preferably the lower outer rail 19 supports the table 12 via a beam 19B.

In order to move the outer rails 19, the user need only push table 12.Alternative, a knob assembly similar to knob assembly 400 may beprovided in base 11. Accordingly, when user rotates knob 154, pinions410 and 411 rotate, moving outer rails 19 in the same direction andspeed.

FIG. 11 illustrates a fifth embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the first and thirdembodiments. The main differences between this embodiment and the thirdembodiment is that: (1) saw unit 13 is disposed below table 12; and/or(2) table 12 is split in order to allow blade 14 to extend therethroughthroughout the range of movement of table 12.

Saw unit 13 may have a riving knife 13K connected thereto so that thecut pieces of workpiece W do not contact each other. The use andinstallation of riving knife 13K is well known in the art.

Preferably water conduit 8 (not shown) is disposed below table 12 forlubricating and cooling the blade 13, as is known in the art.

Persons skilled in the art may recognize other alternatives to the meansdisclosed herein. However, all these additions and/or alterations areconsidered to be equivalents of the present invention.

What is claimed is:
 1. A saw comprising: a base having a first lengthextending generally along a first direction; a table disposed on thebase; a saw unit disposed on the base one of the table and the saw unitbeing movable relative to the base along the first direction over arange which exceeds the first length; a first stationary rail connectedto the base and extending generally along the first direction; a firstmovable rail engaging the first stationary rail and extending generallyparallel to the first stationary rail, the first movable rail beingconnected to the one of the table and saw unit; and a first rackdisposed on the first movable rail, and a first pinion disposed on oneof the base and the first stationary rail, wherein the first pinionmeshes with the first rack so that the first movable rail moves alongthe first direction upon rotation of the first pinion.
 2. The saw ofclaim 1, wherein the first movable rail is slidingly received over thefirst stationary rail.
 3. The saw of claim 1, further comprising: asecond stationary rail connected to the base and extending generallyalong the first direction and substantially parallel to the secondstationary rail; and a second movable rail engaging the secondstationary rail and extending generally parallel to the first movableand second stationary rails, the second movable rail being connected tothe one of the table and saw unit.
 4. The saw of claim 3, wherein thesecond movable rail is slidingly received over the second stationaryrail.
 5. The saw of claim 3, further comprising a second rack disposedon the second movable rail, and a second pinion disposed on the base,wherein the second pinion meshes with the second rack so that the secondmovable rail moves along the first direction upon rotation of the secondpinion.
 6. The saw of claim 1, wherein the saw unit is movable along asecond direction substantially perpendicular to the first direction. 7.The saw of claim 1, wherein the saw unit is substantially above thetable.
 8. The saw of claim 1, wherein the saw unit is substantiallyunderneath the table.